The interest on micro cutting processes is proved by the attention of industries on this topic. This trend moves the researches on micro cutting toward different aspects. A modelling procedure for forecasting cutting forces in microcutting, considering all phenomena involved in micro scale, can be of interest for industries allowing the evaluation of process quality. This paper deals with modelling of cutting forces in micromilling operations of channels. The proposed procedure is a combination of a force model based on specific cutting pressure and instantaneous chip section, estimated considering the tool run-out contribution, an optimisation strategy (particles swarm optimisation), and data coming from experimental tests realised on a sample of titanium alloy (Ti6Al4V). The comparisons between experimental and analytical data, and the evaluation of the uncertainty of the calibrated model show the good ability of the proposed procedure for defining analytical model for force prediction in channels micromilling

The aim of this paper is to study the influence of a Ti6Al4V microstructure on cutting forces during the micromilling process. Samples were annealed above the β-transus at three different temperatures: 1020, 1050, 1080°C and then cooled in a furnace, air and water, in order to produce different Widmastätten microstructures. Micromilling tests were carried out on heat-treated samples and the cutting forces were measured by means of a load cell. The results were correlated to the sample microstructures, which were thoroughly investigated by means of an optical microscope, X-ray diffraction and microhardness measurements. The highest cutting forces were observed for soft and ductile furnace cooled samples, suggesting that the most important factor affecting workability is the material ductility, while hardness is a less relevant parameter

Several industrial fields show a growing interest in producing components with tiny features realized through micro-cutting processes. Micro-cutting processes cannot be considered as simple downscaling of the conventional process since some phenomena, neglected in macro scale, become predominant in micro scale. Nowadays, in micro-cutting field, guidelines suitable for performing standardized machining tests able to evaluate the performance of a micro-cutting process considering the influence of machine-tool, tool holder, tool, workpiece material microstructure, workpiece fixtures and process parameters are not available. The aim of this paper is to propose a testing procedure for micro-milling process defining the set up to be used and the output to be considered. The suggested procedure was applied using an ultra-precision micro milling machine-tool. This machine was characterized through experimental modal analysis for identify its natural frequencies. The test results show the suitability of the proposed guidelines in evaluating the performance of machine-tool and process when micro-milling features are realized.

The growing interest of several industrial fields (biomedical, medical, electronic, defence, aerospace, etc) on miniaturized components leads to an increased interest on micro cutting processes. When approaching these processes, phenomena that can be neglected in macro scale become predominant. For this reason material microstructure, material and geometry of the tool, machine-tool and process parameters must be correctly defined. Another aspect of interest in micro scale cutting is the definition of tests for qualifying the process performance. The present paper aims to propose a testing procedure for evaluating the performance of a micromilling process considering the machine-tool, tool-holder, tool and workpiece fixtures chain. This procedure is based on a series of micro channels realized by consecutive steps. A case of study is reported. The results allows to better understand the performances of the process and of the chain composed by the machine-tool, the tool-holder and the tool